Systems and Methods for Controlling a Climate Control System

ABSTRACT

Methods and related systems are disclosed for retrieving personality data for a first unit a climate control system. In an embodiment, the method includes querying a second unit controller that has replaced the first unit controller. In addition, the method includes determining that the second unit controller lacks personality data that is unique to the first unit. Further, the method includes transferring the personality data to the second unit controller from a memory of the climate control system that is separate from the second unit controller.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

A climate control system, such as a heating, ventilation, andair-conditioning (HVAC) system, may control the environmental conditions(e.g., temperature, relative humidity, etc.) of an indoor space. Aclimate control system may include one or more units (e.g., evaporationunit, condensing unit, furnace unit, etc.) that operate, often inconcert, to adjust or maintain the climate conditions in a defined spaceduring operations. In addition, a climate control system may alsoinclude one or more controllers that are configured to communicate withthe one or more units so as to direct the operation of the units toultimately support the climate control system's functionality andperformance.

BRIEF SUMMARY

Some embodiments disclosed herein are directed to a method of repairinga climate control system that includes a system controller and a firstunit. The first unit includes a first unit controller separate from thesystem controller. In an embodiment, the method includes querying asecond unit controller that has replaced the first unit controller. Inaddition, the method includes determining that the second unitcontroller lacks personality data, wherein the personality datacomprises data that is unique to the first unit. Further, the methodincludes transferring the personality data to the second unit controllerfrom a memory of the climate control system that is separate from thesecond unit controller.

Other embodiments disclosed herein are directed to a non-transitorymachine-readable medium. In an embodiment, the non-transitorymachine-readable medium includes instructions, that when executed by aprocessor, cause the processor to: (a) query a second unit controller ofa first unit of a climate control system for personality data, whereinthe second unit controller has replaced a first unit controller of thefirst unit, and wherein the personality data comprises data that isunique to the first unit; (b) determine that the second unit controllerlacks the personality data; and (c) transfer the personality data to thesecond unit controller from a memory of the climate control system thatis separate from the second unit controller.

Still other embodiments disclosed herein are directed to a method ofcontrolling a climate control system. In an embodiment, the methodincludes (a) receiving personality data from a first unit controller ofa first unit of the climate control system, wherein the personality datacomprises data that is unique to the first unit. In addition, the methodincludes (b) storing the personality data on a memory that is separatefrom the first unit controller. Further, the method includes (c)replacing the first unit controller with a second unit controller, and(d) transferring the personality data of the first unit from the memoryto the second unit controller. Still further, the method includes (e)selecting an operational parameter for the first unit based on thepersonality data after (c) and (d).

Embodiments described herein comprise a combination of features andcharacteristics intended to address various shortcomings associated withcertain prior devices, systems, and methods. The foregoing has outlinedrather broadly the features and technical characteristics of thedisclosed embodiments in order that the detailed description thatfollows may be better understood. The various characteristics andfeatures described above, as well as others, will be readily apparent tothose skilled in the art upon reading the following detaileddescription, and by referring to the accompanying drawings. It should beappreciated that the conception and the specific embodiments disclosedmay be readily utilized as a basis for modifying or designing otherstructures for carrying out the same purposes as the disclosedembodiments. It should also be realized that such equivalentconstructions do not depart from the spirit and scope of the principlesdisclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of various exemplary embodiments, referencewill now be made to the accompanying drawings in which:

FIG. 1 is a diagram of a climate control system according to someembodiments;

FIG. 2 is a flow chart of operating a climate control system accordingto some embodiments; and

FIG. 3 is a flow chart for repairing a climate control system accordingto some embodiments.

DETAILED DESCRIPTION

The following discussion is directed to various exemplary embodiments.However, one of ordinary skill in the art will understand that theexamples disclosed herein have broad application, and that thediscussion of any embodiment is meant only to be exemplary of thatembodiment, and not intended to suggest that the scope of thedisclosure, including the claims, is limited to that embodiment.

The drawing figures are not necessarily to scale. Certain features andcomponents herein may be shown exaggerated in scale or in somewhatschematic form and some details of conventional elements may not beshown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and“comprising” are used in an open-ended fashion, and thus should beinterpreted to mean “including, but not limited to . . . .” Also, theterm “couple” or “couples” is intended to mean either an indirect ordirect connection. Thus, if a first device couples to a second device,that connection may be through a direct connection of the two devices,or through an indirect connection that is established via other devices,components, nodes, and connections. In addition, as used herein, theterms “axial” and “axially” generally mean along or parallel to a givenaxis (e.g., central axis of a body or a port), while the terms “radial”and “radially” generally mean perpendicular to the given axis. Forinstance, an axial distance refers to a distance measured along orparallel to the axis, and a radial distance means a distance measuredperpendicular to the axis. Further, when used herein (including in theclaims), the words “about,” “generally,” “substantially,”“approximately,” and the like mean within a range of plus or minus 10%unless otherwise stated herein.

As used herein, a “climate control system” refers to any system,component, or collection of components that is to alter or affect theclimate conditions (e.g., temperature, relative humidity, etc.) within adefined space (e.g., an interior space of a home, office, retail store,etc.). The term “climate control system” specifically includes (but isnot limited to) air-conditioning systems, heat pump systems, heaters,furnaces, dehumidification systems, HVAC systems, etc. In some climatecontrol systems, a refrigerant may be circulated so as to affect theclimate conditions within the defined space. As used herein a“refrigerant” may refer to any suitable fluid (e.g., heterogeneousfluid, homogeneous fluid, etc.) for use within a refrigeration cyclethat may be incorporated within a climate control system, and maycomprise chlorofluorocarbons, hydrochlorofluorocarbons,hydrofluorocarbons, hydrocarbons, hydrofluoroolefins, or somecombination thereof.

As previously described, a climate control system may include one ormore controllers that are configured to communicate with one or moreunits of the climate control system so as to direct the operation of theunits and therefore ultimately support the climate control system'sfunctionality and performance. Each unit of the climate control systemmay include so-called “personality data” that includes uniqueidentifiers for that particular unit. The personality data may include aparticular model identifier (e.g., name, number, etc.), serial number,and/or other identifying information that is unique to the particularunit in question. The personality data of a given unit may dictate theoperational parameters (e.g., the target values for operation of variouscomponents, applied relationships for unit performance, lookup tabledata, etc.). Thus, the personality data of each unit of the climatecontrol system may dictate the control schemes applied by the one ormore controllers of the climate control system in order to achieve adesired performance or operation. In addition, the personality data mayinclude information related to date(s) of manufacturing, installation,and/or sale of the particular unit, so that warranty information (e.g.,such as warranty status) of a manufacturer's, installers, sellers, etc.warranty may be determined based (at least partially) on the personalitydata.

During the manufacturing process, the personality data of all of theunits may be programmed into the appropriate memories of the climatecontrol system. For instance, in some instances, personality data foreach unit may be stored within a corresponding memory that iscommunicatively coupled to the corresponding unit, and this personalitydata may be accessed by one or more controllers of the climatecontroller during operations as needed. However, during the operatinglife of a climate control system, various components may need to berepaired or even replaced. For instance, replacement of a controller forone or more of the units of the climate control system is a commonoccurrence. Such replacement may result in a loss of the personalitydata for one or more of the units of the climate control system (e.g.,due to removal of the controller and/or a so-called personality modulecoupled thereto). As a result, subsequent operations of the climatecontrol system may be frustrated, because the personality data necessaryfor proper control of the unit's operation is now lost, and a technicianmay need to return to the work site to re-install the previously lostpersonality data.

Accordingly, embodiments disclosed herein include systems and methodsfor so-called “self-healing” within a climate control system(particularly within a control assembly thereof) as a result of areplacement of a memory, or controller, or other device that was theprimary storage location for personality data of one or more of theunits of the climate control system. Thus, through use of the systemsand methods disclosed herein, the climate control system (or acontroller thereof) may retain personality data that may otherwise havebeen lost during a repair or replacement operation.

Referring now to FIG. 1, a schematic diagram of a climate control system100 according to some embodiments is shown. In this embodiment, climatecontrol system 100 is a vapor compression air-conditioning system thatis configured to cool (and possibly dehumidify) an indoor space (e.g.,home, office, retail store, etc.) by circulating a refrigerant so as totransfer heat from the indoor space (not shown) to the outdoorenvironment. However, it should be appreciated that any suitable climatecontrol system (e.g., such as those previously described above) may beutilized in other embodiments.

In this embodiment, the climate control system 100 generally comprises afirst unit 102, and a second unit 104. In some embodiments, the firstunit 102 may be disposed within a building or structure (e.g., such aswithin an attic, utility room, etc.), while the second unit 104 may bedisposed outdoors. As a result, the first unit 102 may be referred to asan “indoor unit” 102, and the second unit 104 may be referred to as an“outdoor unit” 104. However, it should be appreciated that the locationand arrangement of the units 102, 104 may be altered in otherembodiments such that the example locations of units 102, 104 describedherein should not be interpreted as limiting all potential placements orarrangements of the units 102, 104 in various embodiments. For instance,in some embodiments, the indoor unit 102 and the outdoor unit 104 may belocated within the same housing, often exterior to the interior spacethat climate control system 100 is conditioning. Systems where theindoor unit 102 and the outdoor unit 104 are housed together are oftenreferred to as packaged units.

Indoor unit 102 generally comprises an indoor air handling unitcomprising an indoor heat exchanger 108, an indoor fan 110, and anindoor metering device 112. The indoor heat exchanger 108 may generallybe configured to promote heat exchange between refrigerant carriedwithin internal tubing of the indoor heat exchanger 108 and an airflowthat may contact the indoor heat exchanger 108 but that is segregatedfrom the refrigerant. In some embodiments, the indoor heat exchanger 108may comprise a plate-fin heat exchanger. However, in other embodiments,indoor heat exchanger 108 may comprise a microchannel heat exchangerand/or any other suitable type of heat exchanger.

The indoor fan 110 may generally comprise a centrifugal blowercomprising a blower housing, a blower impeller at least partiallydisposed within the blower housing, and a blower motor configured toselectively rotate the blower impeller. The indoor fan 110 may generallybe configured to provide airflow through the indoor unit 102 and/or theindoor heat exchanger 108 to promote heat transfer between the airflowand a refrigerant flowing through the indoor heat exchanger 108. Theindoor fan 110 may also be configured to deliver temperature-conditionedair from the indoor unit 102 to one or more areas and/or zones of anindoor space (not shown). The indoor fan 110 may alternatively comprisea mixed-flow fan and/or any other suitable type of fan. The indoor fan110 may generally be configured as a modulating and/or variable speedfan capable of being operated at many speeds over one or more ranges ofspeeds. In other embodiments, the indoor fan 110 may be configured as amultiple speed fan capable of being operated at a plurality of operatingspeeds by selectively electrically powering different ones of multipleelectromagnetic windings of a motor of the indoor fan 110. In yet otherembodiments, however, the indoor fan 110 may be a single speed fan.

The indoor metering device 112 may generally comprise anelectronically-controlled motor-driven electronic expansion valve (EEV).In some embodiments, however, the indoor metering device 112 maycomprise a thermostatic expansion valve, a capillary tube assembly,and/or any other suitable metering device. Indoor metering device 112may be configured to meter the volume and/or flow rate of refrigerantthrough the indoor metering device 112 during operations.

Referring still to FIG. 1, outdoor unit 104 generally comprises anoutdoor heat exchanger 114, a compressor 116, and an outdoor fan 118.The outdoor heat exchanger 114 may generally be configured to promoteheat transfer between a refrigerant carried within internal passages ortubing of the outdoor heat exchanger 114 and an airflow that contactsthe outdoor heat exchanger 114 but that is segregated from therefrigerant. In some embodiments, outdoor heat exchanger 114 maycomprise a plate-fin heat exchanger. However, in other embodiments,outdoor heat exchanger 114 may comprise a spine-fin heat exchanger, amicrochannel heat exchanger, or any other suitable type of heatexchanger.

The compressor 116 may generally comprise a variable speed scroll-typecompressor that may generally be configured to selectively pumprefrigerant at a plurality of mass flow rates through the indoor unit102, the outdoor unit 104, and/or between the indoor unit 102 and theoutdoor unit 104. In some embodiments, the compressor 116 may comprise arotary type compressor configured to selectively pump refrigerant at aplurality of mass flow rates. In some embodiments, however, thecompressor 116 may comprise a modulating compressor that is capable ofoperation over a plurality of speed ranges, a reciprocating-typecompressor, a single speed compressor, and/or any other suitablerefrigerant compressor and/or refrigerant pump. In some embodiments, thecompressor 116 may be controlled by a compressor drive controller 144,also referred to as a compressor drive and/or a compressor drive system.

The outdoor fan 118 may generally comprise an axial fan comprising a fanblade assembly and fan motor configured to selectively rotate the fanblade assembly. The outdoor fan 118 may generally be configured toprovide airflow through the outdoor unit 104 and/or the outdoor heatexchanger 114 to promote heat transfer between the airflow and arefrigerant flowing through the indoor heat exchanger 108. The outdoorfan 118 may generally be configured as a modulating and/or variablespeed fan capable of being operated at a plurality of speeds over aplurality of speed ranges. In other embodiments, the outdoor fan 118 maycomprise a mixed-flow fan, a centrifugal blower, and/or any othersuitable type of fan and/or blower, such as a multiple speed fan capableof being operated at a plurality of operating speeds by selectivelyelectrically powering different multiple electromagnetic windings of amotor of the outdoor fan 118. In yet other embodiments, the outdoor fan118 may be a single speed fan. Further, in other embodiments, theoutdoor fan 118 may comprise a mixed-flow fan, a centrifugal blower,and/or any other suitable type of fan and/or blower.

As shown in FIG. 1, during operation the climate control system 100 isconfigured to circulate refrigerant between the indoor unit 102 andoutdoor unit 104 (e.g., via lines 120) such that heat may generally beabsorbed by refrigerant at the indoor heat exchanger 108 and rejectedfrom the refrigerant at the outdoor heat exchanger 114. Starting at thecompressor 116, the compressor 116 may be operated to compressrefrigerant and pump the relatively high temperature and high pressurecompressed refrigerant to the outdoor heat exchanger 114, where therefrigerant may transfer heat to an airflow that is passed throughand/or into contact with the outdoor heat exchanger 114 by the outdoorfan 118. After exiting the outdoor heat exchanger 114, the refrigerantflows to the indoor metering device 112, which may controllably expandthe flow of refrigerant such that the refrigerant downstream of theindoor metering device 112 is at a lower pressure and temperature thanthe refrigerant upstream of the indoor metering device 112. From theindoor metering device 112, the refrigerant may enter the indoor heatexchanger 108. As the refrigerant is passed through the indoor heatexchanger 108, heat may be transferred to the refrigerant from anairflow that is passed through and/or into contact with the indoor heatexchanger 108 by the indoor fan 110. Refrigerant leaving the indoor heatexchanger 108 may flow back to the compressor 116, where therefrigeration cycle may begin again.

During operations of the climate control system 100, the variousoperational parameters of the components of the indoor unit 102 andoutdoor unit 104 (e.g., the speed, timing, etc. of the compressor 116,fans 118, 110, opening position of the indoor metering device 112, etc.)may be adjusted so as to achieve a desired operational performance. Adesired operational performance of climate control system 100 may bedefined in a number of different ways and according to a number ofdifferent parameters, such as, for instance, a desired cooling capacity,efficiency, cycle time, leaving air temperature, cooling rate, etc.Accordingly, climate control system 100 includes a control assembly 150including one or more controllers that are to implement various controlalgorithms and methods for the various components of climate controlsystem 100 so as to achieve the desired operating performance aspreviously described above.

In this embodiment, the control assembly 150 includes a first unitcontroller 160 coupled to the indoor unit 102, a second unit controller170 coupled to the outdoor unit 104, and a system controller 152 coupledto each of the unit controllers 160, 170. Because the first unitcontroller 160 and second unit controller 170 are coupled to the indoorunit 102 and outdoor unit 104, respectively, the first unit controller160 may be referred to herein as an “indoor unit controller” 160, andthe second unit controller 170 may be referred to herein as an “outdoorunit controller” 170.

The system controller 152 may generally be configured to selectivelycommunicate with indoor unit controller 160, outdoor unit controller170, and/or other components of the climate control system 100. In someembodiments, the system controller 152 may be configured to controloperation of the indoor unit 102 and/or the outdoor unit 104 via theindoor unit controller 160 and/or outdoor unit controller 170,respectively. In some embodiments, the system controller 152 may beconfigured to monitor and/or communicate, directly or indirectly, with aplurality of sensors associated with components of the indoor unit 102,the outdoor unit 104, etc. The sensors may measure or detect a varietyof parameters, such as, for example, pressure, temperature, and flowrate of the refrigerant as well as pressure and temperature of othercomponents or fluids of or associated with climate control system 100.

The system controller 152 may also be in communication with orincorporated with an input/output (I/O) unit 107 (e.g., a graphical userinterface, a touchscreen interface, or the like) for displayinginformation and for receiving user inputs. The I/O unit 107 may displayinformation related to the operation of the climate control system 100(e.g., from system controller 152) and may receive user inputs relatedto operation of the climate control system 100. During operations, I/Ounit 107 may communicate received user inputs to the system controller152, which may then execute control of climate control system 100accordingly. In some embodiments, the I/O unit 107 may further beoperable to display information and receive user inputs tangentiallyrelated and/or unrelated to operation of the climate control system 100.In some embodiments, however, the I/O unit 107 may not comprise adisplay and may derive all information from inputs from remote sensorsand remote configuration tools (e.g., remote computers, servers,smartphones, tablets, etc.). In some embodiments, system controller 152may receive user inputs from remote configuration tools, and may furthercommunicate information relating to climate control system 100 to I/Ounit 107. In these embodiments, system controller 152 may or may notalso receive user inputs via I/O unit 107. In some embodiments, thesystem controller 152 and/or the I/O unit 107 may be embodied in athermostat that may be disposed within the indoor space.

In some embodiments, the system controller 152 may be configured toselectively communicate with other devices 130 via a communicationnetwork 132. In some embodiments, the communication network 132 maycomprise a telephone network, and the other device 130 may comprise atelephone. In some embodiments, the communication network 132 maycomprise the Internet, and the other device 130 may comprise asmartphone and/or other Internet-enabled mobile telecommunicationdevice. In other embodiments, the communication network 132 and/or theother device 130 may also comprise a remote server.

The indoor unit controller 160 may be carried by the indoor unit 102 andmay generally be configured to receive information inputs, transmitinformation outputs, and/or otherwise communicate with the systemcontroller 152, the outdoor unit controller 170, and/or any other device(e.g., other device 130, I/O unit 107, etc.). In some embodiments, theindoor unit controller 160 may be coupled to an indoor personalitymodule 166 that may comprise personality data that is unique to theindoor unit 102, as previously described above. In some embodiments, theindoor personality module 166 may be incorporated within the indoor unitcontroller 160 itself, such that the personality data of the indoor unit102 may be stored on a memory device of the indoor unit controller 160(e.g., memory 164 described below).

The outdoor unit controller 170 may be carried by the outdoor unit 104and may generally be configured to receive information inputs, transmitinformation outputs, and/or otherwise communicate with the systemcontroller 152, the indoor unit controller 160, and/or any other device(e.g., other device 130, I/O unit 107, etc.). In some embodiments, theoutdoor unit controller 170 may be coupled to an outdoor personalitymodule 176 that may comprise personality data that is unique to theoutdoor unit 104, as previously described above. In some embodiments,the outdoor personality module 176 may be incorporated within theoutdoor unit controller 170 itself, such that the personality data ofthe outdoor unit 104 may be stored on a memory device of the outdoorunit controller 170 (e.g., memory 174 described below).

System controller 152, indoor unit controller 160, and outdoor unitcontroller 170 may each comprise any suitable electric control unit orassembly. Generally speaking, each of the controllers 152, 160, 170 mayeach comprise any suitable device or assembly which is capable ofreceiving electrical (or other data) signals and transmitting electrical(or other data) signals to other devices. In particular, controllers152, 160, 170 may each generally include a processor 154, 162, 172 and amemory 156, 164, 174, respectively. The processors 154, 162, 172 (e.g.,microprocessor, central processing unit, or collection of such processordevices, etc.) may execute machine-readable instructions 155, 165, 175provided on the corresponding memory 156, 164, 174, respectively, (e.g.,non-transitory machine-readable medium) to provide the processors 154,162, 172, respectively, with all of the functionality described herein.The memories 156, 164, 174 of controllers 152, 160, 170, respectivelymay comprise volatile storage (e.g., random access memory), non-volatilestorage (e.g., flash storage, read only memory, etc.), or combinationsof both volatile and non-volatile storage. Data consumed or produced bythe machine-readable instructions, 155, 165, 175 can also be stored onthe memories 156, 164, 174, respectively.

Controllers 152, 160, 170 may communicate with one another and withother components of (or in communication with) climate control system100 (e.g., I/O unit 107, other device 130, network 132, indoor unit 102,outdoor unit 104, etc.) via any suitable medium of communication. Forinstance, controllers 152, 160, 170 may communicate with one another andother components (e.g., such as those mentioned above) via wirelesscommunications (e.g., radio frequency communication, WIFI, BLUETOOTH®,infrared communication, acoustic communication, etc.), wiredcommunication (e.g., metallic wire, fiber optic cable, etc.), or acombination thereof.

Referring still to FIG. 1, during operation of the climate controlsystem 100 (e.g., as refrigerant is circulated between the indoor unit102 and outdoor unit 104 as previously described above), the controlassembly 150 may select or adjust various operating parameters of thecomponents of climate control system 100 as generally described above.More particularly, in some embodiments, the control assembly 150(including the system controller 152, indoor unit controller 160,outdoor unit controller 170) may receive measured variables such as, forinstance pressure, temperature, humidity, flow rate, etc. (ormeasurements or values that are indicative of these variables), and mayimplement various control algorithms, relationships, methods,conversions, etc. so as to adjust one or more operational parameters ofthe components of climate control system 100. For example, duringoperations control assembly 150 may determine a temperature of therefrigerant within the indoor heat exchanger 108, and based on thistemperature, may adjust a position of the indoor metering valve 112, aspeed of the indoor fan 110, outdoor fan 118, compressor 116, etc. so asto achieve or maintain a target value of the refrigerant temperaturewithin the indoor heat exchanger 108.

During these operations, the personality data supplied from thepersonality modules 166, 176 may be utilized to determine how and whatadjustments may be made to the components of the climate control system100 in order to achieve the desired operational performance as describedabove. Specifically, system controller 152, indoor unit controller 160,and/or outdoor unit controller 170 may utilize the personality data ofeither the indoor unit 102 or the outdoor unit 104 so as to determinewhat relationships, algorithms, methods, conversions, etc. to apply soas to effect the overall performance of the climate control system 100in the desired manner. Thus, without this personality data, the controlassembly 150 may be unable to perform (or efficiently perform) controloperations for the climate control system 100 as described above.

At some point, it may become necessary or desirable to replace theindoor unit controller 160 and/or the outdoor unit controller 170. Forinstance, one or more of the unit controllers 160, 170 may becomedamaged (e.g., due to an electrical power surge, physical damage, waterdamage, etc.) or may otherwise cease to work properly or at all withinthe climate control system 100. In some instances, one or both of theindoor unit 102 and the outdoor unit 104 may be replaced with adifferent (e.g., newer) model or type that requires a different designor type of unit controller (e.g., unit controllers 160, 170). Regardlessof the precise reason, if one or both of the unit controllers 160, 170is replaced within climate control system 100, they are typicallyreplaced with a generic replacement controller that includes nopersonality data of the corresponding unit (e.g., indoor unit 102,outdoor unit 104). Specifically, if the personality data is stored on aseparate personality module, such as personality modules 166, 176, thetechnician may mistakenly dispose of the personality module 166, 176along with the damaged, obsolete, or non-working unit controller 160,170, respectively. Alternatively, in embodiments where the personalitydata is stored directly on the memories 165, 175 of the unit controllers160, 170, respectively, the personality data is also lost when thedamaged, obsolete, or non-working unit controller 160, 170 is removedand discarded.

As a result, following the installation of a new or replacement unitcontroller 160, 170, a technician will then need to obtain suitablepersonality data (e.g., via purchase and installation of a newpersonality module, installation of the appropriate personality data onthe memory of the newly installed unit controller, etc.) beforeoperations with climate control system 100 may resume. In someinstances, because personality data is often overlooked by a servicetechnician, a return trip may need to be scheduled for the technician tothe worksite in order to subsequently install or input the requiredpersonality data as described above. Accordingly, as will be describedin more detail below, the embodiments disclosed herein include methodsand techniques for internally retaining the personality data of thevarious units (e.g., indoor unit 102, outdoor unit 104) of the climatecontrol system 100 so that if a unit controller 160, 170 is laterreplaced and suitable personality data is not included with the replacedunit controller, the climate control system 100 (and particularly thecontrol system 150) may retrieve the previously stored personality dataand transfer it to the replacement unit controller. As a result, thecontrol system 150 of climate control system 100 may be self-healingwith respect to the retrieval of otherwise lost personality datafollowing a unit controller replacement. Further details of embodimentsof these methods are now described below. In order to better describethe features of these methods, continuing reference will be made to theclimate control system 100 shown in FIG. 1 and described above, and thefeatures of the following methods may be described with specificreference to the components of climate control system 100. However, itshould be appreciated that the following methods may be applied to anysuitable climate control system that utilizes personality data for theoperation of the units and components therein. Accordingly, anyreference to the climate control system 100 in the following descriptionis meant merely to clarify and explain the features of the disclosedmethods via a particular implementation, and should therefore not beinterpreted as limiting all potential uses and implementations of thedisclosed methods.

Referring now to FIG. 2, a method 200 of operating a climate controlsystem (e.g., climate control system 100) is shown. In some embodiments,method 200 may represent a method of operating the climate controlsystem upon initial power up of the system following installation.However, it should be appreciated that method 200 may be performed atany point during the operation of the climate control system. In someembodiments, the method 200 may be repeatedly performed throughout theoperational life of the climate control system, such as, for instance,at regular time intervals (e.g., days, months, years, etc.), after aloss of electrical power to one or more components of the climatecontrol system, etc.

Initially, method 200 includes receiving personality data from each unitcontroller of a climate control system at block 202. Specifically, inthe climate control system 100 of FIG. 1, the personality data may bereceived from the indoor unit controller 160 and outdoor unit controller170, which may obtain the personality data from the memories 165, 175,or via the personality modules 166, 176 coupled to the unit controllers160, 170, respectively. The personality data may be received withinanother controller of the climate control system 100, such as in thesystem controller 152, and/or may be received by one or more otherdevices, such as, for instance other device 130, I/O unit 107, etc. Insome embodiments, the personality data of one unit 102, 104 may bereceived by the unit controller 160, 170 of the other unit 102, 104,respectively at block 202.

Referring still to FIG. 2, method 200 next includes storing the receivedpersonality data from each unit controller in a memory that is separatefrom each corresponding unit controller at block 204. In someembodiments, method 200 includes storing the received personality datain non-volatile storage. For the climate control system 100 of FIG. 1,the personality data received from the unit controllers 160, 170 may bestored on the memory 156 of system controller 152 and/or suitablememories of the other device 130, I/O unit 107, etc. In someembodiments, the personality data received from one unit (e.g., theindoor unit 102, outdoor unit 104) may be stored on the memory of a unitcontroller (e.g., unit controllers 160, 170) of another unit within theclimate control system 100. In some embodiments, the personality data ofeach unit (e.g., indoor unit 102, outdoor unit 104 of the climatecontrol system 100) may be stored on a plurality of different memorieswithin the climate control system at block 204.

Referring again to FIG. 2, following the storage of the personality dataat block 204, method 200 ends. Thereafter, normal operations with theclimate control system may be conducted. For the climate control system100 of FIG. 1, during these post-method 200 operations, the controlassembly 150 may control the various operating parameters of the climatecontrol system 100 utilizing the personality data as stored in the unitcontrollers 160, 170 (and/or personality modules 166, 176) as previouslydescribed above.

Referring now to FIG. 3, a method 300 of repairing a climate controlsystem (e.g., climate control system 100) is shown. In some embodiments,method 300 may be performed after the method 200 (FIG. 2) was previouslyperformed.

Initially, method 300 includes replacing a first unit controller of afirst unit of a climate control system with a second unit controller at302. For instance, in the climate control system 100 of FIG. 1, block302 may comprise replacing at least one of the unit controllers 160, 170of the indoor unit 102, outdoor unit 104, respectively. As previouslydescribed, such a replacement may be completed so as to replace adamaged or otherwise non-functioning unit controller, as part of ageneral replacement of one of the indoor unit 102, outdoor unit 104,etc. The “second unit controller” in block 302 may correspond to areplacement unit controller that is to replace either the indoor unitcontroller 160 or the outdoor unit controller 170.

Referring again to FIG. 3, method 300 next includes querying the secondunit controller for personality data of the first unit at 304. For theclimate control system 100 of FIG. 1, block 304 may comprise queryingthe replacement unit controller (e.g., a replacement of the indoor unitcontroller 160, outdoor unit controller 170, etc.) for personality dataof the corresponding unit (e.g., indoor unit 102, outdoor unit 104,etc.). In some embodiments, the system controller 152 may query to newunit controller for personality data, or another device of or coupled tothe climate control system 100 may query the new unit controller atblock 304 (e.g., such as device 130, I/O unit 107, etc.).

Referring again to FIG. 3, method 300 next includes determining whetherthe second unit controller has personality data of the first unit at 306as a result of the query at block 304. For the climate control system100 in FIG. 1, if the replacement unit controller of either the indoorunit controller 160 or the outdoor unit controller 170 (i.e., the“second unit controller” in method 300) does include personality dataeither in a coupled personality module (e.g., personality modules 166,176) or stored within the memory of the replacement unit controller(e.g., memories 165, 175), then the determination at block 306 is thatthe replacement control unit does include personality data of thecorresponding unit. If, on the other hand, the replacement unitcontroller does not include personality data either in a coupledpersonality module or stored within the memory of the replacement unitcontroller, then the determination at block 306 is that the replacementunit controller does not include personality data of the correspondingunit.

Returning to FIG. 3, if the determination at block 306 is “yes” (i.e.,the second unit controller does include personality data of the firstunit), then method 300 proceeds to block 308 and the personality datastored on the second unit controller is stored on a memory that isseparate from the second unit controller. Specifically, as is similarlydescribed above for block 204 of method 200 (FIG. 2), if the secondcontrol unit includes personality data of the first unit (e.g., eitherbecause it was previously installed onto a memory of the second unitcontroller or was included in a personality module that is coupled tothe second unit control unit as previously described), then it may bepresumed (at least for purposes of the method 300) that the second unitcontroller is a controller of a new or different first unit (i.e.,different in model, type, arrangement, etc. than the original first unitincluded within the climate control system). Thus, upon determining thatthe second unit controller has personality data for the first unit, thepersonality data is retrieved and stored on a memory that is separatefrom the second unit controller itself. For instance, for the climatecontrol system 100 of FIG. 1, the newly obtained personality data may beretrieved from the second unit controller and stored (e.g., innon-volatile storage) on the memory 156 of system controller 152 and/orsuitable memories of the other device 130, I/O unit 107, etc. Inaddition, as was previously described above, in some embodiments, thepersonality data of the unit associated with the replaced unitcontroller (i.e., the “second unit” controller in method 300) may bestored on the memory of the other unit controllers within the climatecontrol system (e.g., such as unit controller 160, 170, etc.) either inlieu of or in addition to the memory of the system controller 152,device 130, I/O unit 107, etc. In some embodiments, the personality dataof the unit associated with the replaced unit controller may overwriteany previously stored personality data of the unit already stored on thememory at block 308 (e.g., such as personality data that was previouslystored via block 204 in method 200 in FIG. 2) so as to avoid duplicate(and possibly inconsistent) personality data for the unit on the memory.

If, on the other hand, the determination at block 306 is “no” (i.e., thesecond unit controller does not include personality data of the firstunit), then method 300 proceeds to block 310 in which personality dataof the first unit is transferred to the second unit controller from amemory that is separate from the second unit controller. The memory atblock 310 may be any one or more of the same memories mentioned abovefor block 308. Thus, for the climate control system 100 of FIG. 1, thememory at block 310 may comprise the memory 156 of system controller150, device 130, I/O unit 107, the memories 164, 174 of unit controllers160, 170, etc. In some embodiments, the personality data that istransferred from the separate memory at block 310 may have beenpreviously stored within the separate memory via performance of themethod 200 in FIG. 2. In other embodiments, the personality data that istransferred from the separate memory may have been previously stored inthe separate memory during the initial construction or installation ofthe climate control system 100 (i.e., prior to first operation orenergization of the climate control system 100). Thus, if it isdetermined that the replaced unit controller does not have personalitydata for the corresponding unit (e.g., at block 308) then it may bedetermined (at least for purposes of method 300) that the unit coupledto the newly replaced unit controller (i.e., the so-called “second unitcontroller” in method 300) is the same unit that was coupled to theoriginal or previously utilized unit controller (i.e., the so-called“first unit controller” in method 300) so that the previously storedpersonality data may be utilized to operate the unit following thereplacement of the unit controller as described above.

Referring again to FIG. 3, following both blocks 308 and 310, in someembodiments method 300 proceeds to block 312 to select at least oneoperating parameter for the first unit based on the personality data ofthe first unit from either the second unit controller or the memory.Specifically, if method 300 progresses to block 312 via block 308, thenthe personality data utilized at block 312 comprises the personalitydata that was retrieved from the second unit controller as described forblock 308. If, on the other hand, method 300 progresses to block 312 viablock 310, then the personality data utilized at block 312 comprises thepersonality data that was retrieved from the separate memory andtransferred to the second unit controller as described for block 310.

In some embodiments, method 300 may also include storing personalitydata of a second unit of the climate control system (i.e., personalitydata that is unique to the second unit) on the second unit controller ofthe first unit. As a result, once the personality data of the secondunit is stored on the second unit controller of the first unit, thesecond unit controller may thereafter provide the personality data ofthe second unit to a replacement unit controller of the second unit(e.g., such as in the manner described above for block 310).

In some embodiments, following both blocks 308 and 310, method 300 mayproceed to determine a warranty status for the first unit based on thepersonality data of the first unit from either the second unitcontroller or the memory. Specifically, as previously described,personality data may include information related to the date ofmanufacturing, installation, and/or sale of a unit (e.g., the firstunit) such that a warranty status (e.g., whether the first unit iscurrently covered under a manufacturers and/or installer's warranty) maybe determined based on the personality data.

Embodiments disclosed herein include systems and methods for so-called“self-healing” within a climate control system as a result of areplacement of a memory or controller within the climate control systemthat was the primary storage location for personality data of one ormore of the units of the climate control system. Thus, through use ofthe systems and methods disclosed herein, the climate control system (ora controller thereof) may retain personality data that may otherwisehave been lost during a repair or replacement operation.

While embodiments disclosed herein have specifically described a climatecontrol system 100 that is configured as a vapor-compressionair-conditioning system, it should be appreciated that other types ofclimate control systems may be utilized in some embodiments. Forinstance, in some embodiments, the climate control system 100 may beconfigured as a so-called “heat pump” whereby the flow direction of therefrigerant may be reversed from that shown in FIG. 1 and describedabove so as to increase a temperature of the indoor space (not shown).In these embodiments, the climate control system 100 may additionallyinclude a so-called reversing valve that is to selectively reverse theflow direction of the refrigerant between the indoor unit 102 andoutdoor unit 104. In addition, in these embodiments, the climate controlsystem 100 may also include an outdoor metering device within theoutdoor unit 104 that is substantially similar to the indoor meteringdevice 112 described above, and that is to controllably meter the flowof refrigerant before it enters the outdoor heat exchanger 114.

In addition, as previously described above, some embodiments of climatecontrol system 100 may comprise a so-called “packaged unit,” whereby theindoor unit 102 and the outdoor unit 104 may be located within the samehousing. However, during the operational life of such a climate controlsystem, replacement of a unit controller of either the indoor unit 102and/or outdoor unit 104 (e.g., by replacement of the entire packagedunit or a portion thereof) may result in the loss of personality data insubstantially the same manner as described above. Thus, embodiments ofmethods 200, 300 may be performed so as to allow a climate controlsystem employing a packaged unit to “self-heal” and thus retrieve theotherwise lost personality data in substantially the same manner asdescribed above.

In other embodiments, the systems and methods disclosed herein may alsoapply to a heater (e.g., electric coil heater, combustion furnace,etc.). In these embodiments, a replacement of a unit controller for aunit of the heater (e.g., a unit control unit for the electric coilheater, combustion furnace, etc.) may result in the loss of personalitydata in a similar manner to that described above for the indoor unit 102and outdoor unit 104 of climate control system 100. As a result,embodiments of methods 200, 300 may be performed so as to allow theheater to “self-heal” and thus retrieve the otherwise lost personalitydata in substantially the same manner as described above.

While exemplary embodiments have been shown and described, modificationsthereof can be made by one skilled in the art without departing from thescope or teachings herein. The embodiments described herein areexemplary only and are not limiting. Many variations and modificationsof the systems, apparatus, and processes described herein are possibleand are within the scope of the disclosure. Accordingly, the scope ofprotection is not limited to the embodiments described herein, but isonly limited by the claims that follow, the scope of which shall includeall equivalents of the subject matter of the claims. Unless expresslystated otherwise, the steps in a method claim may be performed in anyorder. The recitation of identifiers such as (a), (b), (c) or (1), (2),(3) before steps in a method claim are not intended to and do notspecify a particular order to the steps, but rather are used to simplifysubsequent reference to such steps.

1. A method of repairing a climate control system, the climate control system comprising a system controller and a first unit, the first unit including a first unit controller separate from the system controller, the method comprising: (a) querying a second unit controller that has replaced the first unit controller; (b) determining that the second unit controller lacks personality data, wherein the personality data comprises data that is unique to the first unit; (c) transferring the personality data to the second unit controller from a memory of the climate control system that is separate from the second unit controller; (e1) controlling the operation of the first unit using the second unit controller; (e2) selecting an operational parameter for the first unit based on the personality data transferred to the second unit controller; and (e3) operating the first unit at a speed of a fan or a compressor of the first unit based on the operation parameter selected.
 2. The method of claim 1, comprising: (d) storing the personality data on the second unit controller.
 3. (canceled)
 4. (canceled)
 5. The method of claim 1, wherein the memory is a memory of the system controller.
 6. The method of claim 1, wherein the memory is a memory of a third unit controller of a second unit of the climate control system.
 7. The method of claim 6, comprising transferring second unit personality data to the second unit controller, wherein the second unit personality data comprises data that is unique to the second unit.
 8. The method of claim 1, wherein the first unit includes a heat exchanger that is configured to receive a flow of refrigerant therethrough.
 9. The method of claim 1, wherein the personality data includes a serial number of the first unit.
 10. A non-transitory machine-readable medium including instructions, that when executed by a processor, cause the processor to: (a) query a second unit controller of a first unit of a climate control system for personality data, wherein the second unit controller has replaced a first unit controller of the first unit, and wherein the personality data comprises data that is unique to the first unit; (b) determine that the second unit controller lacks the personality data; (c) transfer the personality data to the second unit controller from a memory of the climate control system that is separate from the second unit controller; (d) control the operation of the first unit using the second unit controller; (e) select an operational parameter for the first unit based on the personality data transferred in (c); and (f) operate the first unit at a speed of a fan or a compressor of the first unit based on the operation parameter selected.
 11. (canceled)
 12. (canceled)
 13. The non-transitory machine-readable medium of claim 10, wherein the personality data comprises a serial number of the first unit.
 14. The non-transitory machine-readable medium of claim 10, wherein the instructions, when executed by the processor, further cause the processor to: (g) retrieve and store the personality data from the first unit controller on the memory before (a)-(c).
 15. A method of controlling a climate control system, the method comprising: (a) receiving personality data from a first unit controller of a first unit of the climate control system, wherein the personality data comprises data that is unique to the first unit; (b) storing the personality data on a memory that is separate from the first unit controller; (c) replacing the first unit controller with a second unit controller; (d) transferring the personality data of the first unit from the memory to the second unit controller; (e) selecting an operational parameter for the first unit based on the personality data after (c) and (d); and (f) operating the first unit at a speed of a fan or a compressor of the first unit based on the operation parameter selected.
 16. The method of claim 15, wherein the memory is disposed within a system controller of the climate control system that is separate from the first unit controller and the second unit controller.
 17. The method of claim 15, wherein the memory is disposed within a third unit controller of a second unit of the climate control system.
 18. The method of claim 15, wherein the first unit includes a heat exchanger configured to receive a flow of refrigerant therethrough.
 19. The method of claim 15, wherein the personality data of the first unit comprises a serial number of the first unit.
 20. (canceled)
 21. The method of claim 1, wherein (e1) further comprises selecting the operational parameter using the system controller.
 22. The non-transitory machine-readable medium of claim 11, wherein (e) further causes the processor to select the operational parameter using a system controller.
 23. The method of claim 15, wherein (e) further comprises selecting the operational parameter using a system controller.
 24. The method of claim 1, wherein the personality data includes an installation date for the first unit, and the method further includes transmitting the installation date to a communication network.
 25. The non-transitory machine-readable medium of claim 11, wherein the personality data includes an installation date for the first unit, and the method further includes transmitting the installation date to a communication network. 